CN116281334A

CN116281334A - Coiled material tension control system and control method

Info

Publication number: CN116281334A
Application number: CN202310457203.2A
Authority: CN
Inventors: 蔡剑平; 蔡云鹏
Original assignee: Suzhou Zhida Electrical Technology Co ltd
Current assignee: Suzhou Zhida Electrical Technology Co ltd
Priority date: 2023-04-26
Filing date: 2023-04-26
Publication date: 2023-06-23

Abstract

The invention discloses a coiled material tension control system and a control method, wherein the method comprises the following steps: collecting the linear speed and the angular speed of a coiled material, and calculating the data of the coil diameter ratio; collecting the tension of the coiled material, and calculating tension deviation information between the tension and a set tension reference value; PID adjustment is carried out on the tension deviation information, and a PID correction result is output; performing operation processing on the real-time linear velocity information and the PID correction result to obtain a linear velocity deviation value; judging whether a preset acceleration compensation enabling condition, a preset deceleration compensation enabling condition and/or a preset deceleration elongation compensation enabling condition are met, and if so, outputting a speed compensation value; calculating a linear velocity calibration target value according to a preset linear velocity reference value, a linear velocity deviation value and a velocity compensation value; the linear velocity calibration target value and the coil diameter ratio data are subjected to DIV operation, and the output rotating speed of the driving mechanism for coiling and uncoiling the coiled material is controlled according to the DIV operation result, so that the tension of the coiled material can be stably controlled in the process of the change of the large, medium and small shaft diameters and acceleration and deceleration of the coiled material.

Description

Coiled material tension control system and control method

Technical Field

The invention relates to the field of coiled material winding and unwinding control, in particular to a coiled material tension control system and a coiled material tension control method.

Background

In the coil winding and unwinding process, the coil diameter of the coil is in a continuously changing state: during unreeling, the reeling diameter is continuously reduced; during the winding process, the winding diameter is continuously increased. During acceleration and deceleration, variations in the mathematical model of the control system are caused by variations in the inertia and acceleration, deceleration and mechanical losses of the web, resulting in instability of the tension control. In order to solve this problem, it is required to dynamically compensate the control system and control the fluctuation of the tension.

At present, the main control mode is that the tension of a winding and unwinding device is calculated through a computer or a PLC, the diameter of the winding and unwinding device is calculated at the same time, and the current moment is calculated according to M=F×R, wherein M represents moment, F represents the tension of a wire sheet, R represents the radius of winding or unwinding, so as to control the tension of a coiled material.

This control has at least the following drawbacks:

1. in acceleration and deceleration, diameter calculation and torque control have hysteresis, and cannot be tracked in real time, so that tension is unstable, a coiled material is loose or too tight, and poor product quality is caused;

2. when different raw materials are replaced, the inertia of the system is changed greatly due to the difference of the raw materials, so that the tension of the coiled material is unstable;

3. when the coils are in different diameters, the inertia of the system is changed greatly, and the system is changed from linearity to nonlinearity, so that the system is unstable and the tension of the coils is unstable.

The above disclosure of background art is only for aiding in understanding the inventive concept and technical solution of the present invention, and it does not necessarily belong to the prior art of the present patent application, nor does it necessarily give technical teaching; the above background should not be used to assess the novelty and creativity of the present application without explicit evidence that the above-mentioned content was disclosed prior to the filing date of the present patent application.

Disclosure of Invention

The invention aims to provide a coiled material tension control system and a control method, which can stably control the winding and unwinding rotating speed of coiled materials to control the tension to keep a stable range in the process of large, medium and small shaft diameter change and acceleration and deceleration.

In order to achieve the above purpose, the invention adopts the following technical scheme:

a web tension control system for controlling tension of a web during a winding and unwinding process, the system comprising a main controller and the following modules:

the tension compensation adjusting module is configured with a tension deviation sub-module, a roll diameter ratio calculating sub-module and a PID adjusting sub-module, wherein the PID adjusting sub-module obtains a PID correction result according to tension deviation information output by the tension deviation sub-module, and the roll diameter ratio calculating sub-module calculates roll diameter ratio data according to real-time linear speed and angular speed information;

the speed compensation adjustment module is configured with one or more of an acceleration compensation sub-module, a deceleration compensation sub-module and a deceleration elongation compensation sub-module, and if the acceleration compensation enabling condition preset by the acceleration compensation sub-module is met, the acceleration compensation sub-module outputs a preset acceleration compensation value; if the preset deceleration compensation enabling condition of the deceleration compensation submodule is met, the deceleration compensation submodule outputs a preset deceleration compensation value; if the preset deceleration extension compensation enabling condition of the deceleration extension compensation submodule is met, the deceleration extension compensation submodule outputs a preset deceleration extension compensation value; if the acceleration compensation enabling condition, the deceleration compensation enabling condition and the deceleration elongation compensation enabling condition are not met, the speed compensation adjusting module outputs a speed compensation value of zero;

the master controller of the web tension control system is configured to:

performing operation processing on the real-time linear velocity information and the PID correction result to obtain a linear velocity deviation value;

calculating a linear velocity calibration target value according to a preset linear velocity reference value, the linear velocity deviation value and a velocity compensation result output by the velocity compensation adjustment module;

and performing DIV operation on the linear velocity calibration target value and the coil diameter ratio data, and controlling the output rotating speed of the coil coiling and uncoiling driving mechanism according to the DIV operation result.

Further, in any one or a combination of the foregoing technical solutions, the tension compensation adjustment module is further configured with an inertia adjustment sub-module, which predicts the degree of inertia compensation of the coiled material according to the physical parameters of the coiled material, and adjusts the proportion value P of the PID adjustment sub-module according to the inertia of the coiled material.

Further, in any one or a combination of the foregoing technical solutions, the system pre-constructs a mapping relationship between a coil diameter value and a scaling factor, and the coil diameter ratio calculating submodule is further configured to calculate a coil diameter value according to real-time linear velocity and angular velocity information;

and adjusting the proportion value P of the PID adjustment sub-module according to the proportion adjustment coefficient corresponding to the coiled material diameter value.

Further, in combination with any one or more of the preceding claims, the tension compensation adjustment module is further configured to output the real-time linear velocity; the system calculates the acceleration value of the coiled material according to the real-time linear velocity;

if the acceleration value is larger than a preset first acceleration threshold value which is a positive number, the acceleration compensation enabling condition is reached;

if the acceleration value is smaller than a preset second acceleration threshold value which is a negative number, the deceleration compensation enabling condition is reached;

and if the duration that the acceleration value is maintained in the preset tolerance threshold range reaches a preset time threshold, the deceleration elongation compensation enabling condition is reached, wherein the lower limit value of the tolerance threshold range is larger than the second acceleration threshold, and the upper limit value of the tolerance threshold range is smaller than the first acceleration threshold.

Further, the system according to any one or combination of the preceding claims, further comprising a linear velocity sensor configured to detect a real-time linear velocity and an angular velocity sensor configured to detect a real-time angular velocity.

According to another aspect of the present invention, there is provided a web tension control system for controlling tension of a web during winding and unwinding, the system comprising a main controller and the following modules:

the master controller of the web tension control system is configured to:

performing DIV operation on the real-time linear velocity information and the roll diameter ratio data to obtain a DIV operation result; and the DIV operation result and the PID correction result are subjected to operation processing to obtain a rotating speed deviation value;

performing DIV operation on the speed compensation result output by the speed compensation adjustment module and the roll diameter ratio data to obtain a rotation speed compensation value;

performing DIV operation on a preset linear speed reference value and the reel diameter ratio data to obtain a rotating speed reference value;

calculating a rotation speed calibration target value according to the rotation speed reference value, the rotation speed deviation value and the rotation speed compensation value;

and controlling the output rotating speed of the driving mechanism for winding and unwinding the coiled material according to the rotating speed calibration target value.

Further, taking any one or a combination of the above technical solutions as a rule, performing DIV operation on the speed compensation result and the roll diameter ratio data output by the speed compensation adjustment module, and performing DIV operation on a preset linear speed reference value and the roll diameter ratio data to obtain two independent operation processes;

or, performing a DIV operation on the speed compensation result output by the speed compensation adjustment module and the roll diameter ratio data, and performing a DIV operation on a preset linear speed reference value and the roll diameter ratio data as an integral operation process, including: performing operation processing on a preset linear velocity reference value and the velocity compensation result to obtain a compensated linear velocity target value; and performing DIV operation on the compensated linear velocity target value and the roll diameter ratio data.

Further, taking any one or a combination of the above technical solutions as a combination, performing DIV operation on the real-time linear velocity information and the roll diameter ratio data, and performing DIV operation on a preset linear velocity reference value and the roll diameter ratio data to obtain two independent operation processes;

or, performing a DIV operation on the real-time linear velocity information and the roll diameter ratio data, and performing a DIV operation on a preset linear velocity reference value and the roll diameter ratio data, where the DIV operation process includes: performing operation processing on a preset linear velocity reference value and the real-time linear velocity information to obtain a corrected deviation linear velocity target value; and performing DIV operation on the linear velocity target value after the correction deviation and the roll diameter ratio data.

According to still another aspect of the present invention, there is provided a web tension control method comprising the steps of:

acquiring linear speed and angular speed information of a coiled material in real time, and calculating the coil diameter ratio data; collecting the tension of the coiled material in real time, and calculating tension deviation information between the tension and a set tension reference value;

PID adjustment is carried out on the tension deviation information, and a PID correction result is output;

judging whether a preset acceleration compensation enabling condition, a preset deceleration compensation enabling condition and/or a preset deceleration elongation compensation enabling condition are met, and if so, outputting a speed compensation value;

calculating a linear velocity calibration target value according to a preset linear velocity reference value, the linear velocity deviation value and the velocity compensation value;

In addition, the invention also provides another coiled material tension control method, which comprises the following steps:

performing DIV operation on the real-time linear velocity information and the roll diameter ratio data to obtain a DIV operation result;

performing operation processing on the DIV operation result and the PID correction result to obtain a rotating speed deviation value;

performing DIV operation on the speed compensation value and the roll diameter ratio data to obtain a rotation speed compensation value;

Further, performing DIV operation on the real-time linear velocity information and the roll diameter ratio data, performing DIV operation on the velocity compensation value and the roll diameter ratio data, and performing DIV operation on a preset linear velocity reference value and the roll diameter ratio data to obtain independent operation processes;

or, performing a DIV operation on the speed compensation value and the roll diameter ratio data output by the speed compensation adjustment module, and performing a DIV operation on a preset linear speed reference value and the roll diameter ratio data into an integral operation process, including: performing operation processing on a preset linear velocity reference value and the velocity compensation value to obtain a compensated linear velocity target value; performing DIV operation on the compensated linear velocity target value and the roll diameter ratio data;

The technical scheme provided by the invention has the following beneficial effects:

a. the PID control mode is adopted to calculate the speed deviation value for controlling tension stability, and the speed compensation value for controlling tension stability is also calculated, so that a solution for jointly controlling the tension of the coiled material is formed, the stability is high, and the adaptive tension control solution can be automatically switched no matter how the coiled material is changed;

b. factors of inertia change are included in the tension control strategy, and proportional values of PID control are adjusted in real time, so that stability and precision of coiled material tension control are further improved, and further product quality is stable;

c. the tension control system and the tension control method are suitable for coiled materials with elongation performance and zero-elongation coiled materials, and have wide application scenes.

Drawings

In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings that are required to be used in the embodiments or the description of the prior art will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments described in the present application, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.

FIG. 1 is a schematic frame diagram of a first web tension control system provided in accordance with an exemplary embodiment of the present invention;

FIG. 2 is a schematic diagram of a frame of a tension compensation adjustment module provided in accordance with an exemplary embodiment of the present invention;

FIG. 3 is a schematic diagram of a frame of a speed compensation adjustment module provided in accordance with an exemplary embodiment of the present invention;

FIG. 4 is a diagram of a PID controlled scaling factor adjustment architecture in a tension compensation adjustment module according to an exemplary embodiment of the invention;

fig. 5 is a schematic frame diagram of a second web tension control system provided in accordance with an exemplary embodiment of the present invention.

Detailed Description

In order that those skilled in the art will better understand the present invention, a technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in which it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the present invention without making any inventive effort, shall fall within the scope of the present invention.

It should be noted that the terms "first," "second," and the like in the description and the claims of the present invention and the above figures are used for distinguishing between similar objects and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used may be interchanged where appropriate such that the embodiments of the invention described herein may be implemented in sequences other than those illustrated or otherwise described herein. Furthermore, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, apparatus, article, or device that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed or inherent to such process, method, article, or device.

In one embodiment of the invention, a coil tension control system is provided for controlling tension of a coil in a coiling and uncoiling process, as shown in fig. 1, the system comprises a main controller, a tension compensation adjustment module and a speed compensation adjustment module, wherein the tension compensation adjustment module outputs a speed deviation value DeltaV, the speed compensation adjustment module outputs a speed compensation value (comprising acceleration/deceleration compensation and deceleration elongation speed compensation in fig. 1) and a speed reference value, and the linear speed deviation value DeltaV, the speed compensation value and the speed reference value are subjected to addition processing to obtain a linear speed calibration target value; the linear velocity calibration target value and the coil diameter ratio data of the coiled material are subjected to DIV processing to obtain a target rotating speed, so that the output rotating speed of a motor for driving the coiled material to rotate is controlled. The roll diameter ratio data of the coiled material is calculated by a tension compensation adjusting module.

The working principle of the system is as follows:

the user sets the tension value of the curl or the unwind through the touch screen. During operation of the apparatus, tension changes in the web are detected by the tension sensor. After receiving the set tension value, the PLC or the computer compares the detected tension with the set tension value to obtain a tension difference, and adjusts the executive component through a PID algorithm to change the rotating speed of the executive component so as to control the tension.

In order to further maintain the control of constant tension or improve the stability of tension control, the diameter detection and calculation functions of coiled materials are added, and the diameter of the coiled materials is calculated in real time when the coiled materials are different in size. The diameter measurement method is that the linear speed of the coiled material is detected in real time, and the angular speed of the coiled material is detected at the same time. The coil diameter ratio calculating module calculates the actual coil diameter ratio by using the linear speed and the angular speed, controls the executing element, changes the rotation moment and the angular speed, and realizes the constant linear speed control.

In practice, in particular during the unwinding and unwinding of textile devices, such as filament winding and unwinding devices. At the starting speed of 0m/min, the speed is accelerated to more than 1000m/min, the acceleration time is within 40s, and the deceleration time is within 11 s. In the acceleration and deceleration process, the control system is required to be stable, and the tension is required to be stable. Meanwhile, in the unreeling and curling processes, along with the change of the diameter of a coiled material, the inertia change of the material for reeling and unreeling is very large, low tension control needs to be performed in real time, compensation of speed difference during reeling and unreeling needs to be considered when acceleration and deceleration are needed, and when raw materials of different materials are replaced, the inertia compensation needs to be considered when the raw materials of different materials are different in diameter, so that stable tension control and constant linear speed control are achieved.

Referring specifically to fig. 2, the tension compensation adjustment module includes a tension deviation sub-module, a roll diameter ratio calculation sub-module, and a PID adjustment sub-module, where the PID adjustment sub-module obtains a PID correction result according to tension deviation information output by the tension deviation sub-module, and the roll diameter ratio calculation sub-module calculates to obtain roll diameter ratio data according to real-time linear velocity and angular velocity information; and carrying out operation processing on the real-time linear velocity information and the PID correction result to obtain the linear velocity deviation value delta V. The system further comprises a linear speed sensor and an angular speed sensor, wherein real-time linear speed information is acquired by the linear speed sensor, and real-time angular speed information is acquired by the angular speed sensor.

Referring specifically to fig. 3, the speed compensation adjustment module includes an acceleration compensation sub-module, a deceleration compensation sub-module, and a deceleration elongation compensation sub-module; if the acceleration compensation enabling condition preset by the acceleration compensation submodule is met, the acceleration compensation submodule outputs a preset acceleration compensation value; if the preset deceleration compensation enabling condition of the deceleration compensation submodule is met, the deceleration compensation submodule outputs a preset deceleration compensation value; and if the preset deceleration elongation compensation enabling condition of the deceleration elongation compensation submodule is reached, outputting a preset deceleration elongation compensation value by the deceleration elongation compensation submodule. The basis for specifically judging whether the three enabling conditions are met is as follows:

as shown in fig. 2, the tension compensation adjustment module is further configured to output the real-time linear velocity; the system calculates the acceleration value of the coiled material according to the real-time linear velocity;

As described above, the acceleration compensation value, the deceleration compensation value and the deceleration elongation speed compensation value are all the speed compensation items output by the speed compensation adjustment module; and if the acceleration compensation enabling condition, the deceleration compensation enabling condition and the deceleration elongation compensation enabling condition are not met, outputting a speed compensation value of zero by the speed compensation adjusting module.

In one embodiment, the tension compensation adjustment module is further configured with an inertia adjustment sub-module, which predicts the inertia compensation degree of the coiled material according to the physical parameters of the coiled material, for example, for different materials, when the coiled material is in a large, medium or small diameter, different values of P (proportion) are taken according to an inertia curve, as shown in fig. 4, and the system adjusts the proportion value P of the PID adjustment sub-module according to the inertia of the coiled material.

In one embodiment, the system pre-constructs a mapping relationship between the coil diameter value and the proportional adjustment coefficient, such as a coil diameter-proportional adjustment coefficient curve shown in fig. 4, and the coil diameter ratio calculating submodule is further configured to calculate a coil diameter value according to real-time linear velocity and angular velocity information;

in order to ensure the stability of the PID control system during acceleration and deceleration and different materials and diameters. The stability of the control system and the linear control of the nonlinear system are controlled by adopting different numerical control of P (proportion). As shown in fig. 4, the system adjusts the proportion value P of the PID adjustment sub-module according to the proportion adjustment coefficient corresponding to the coil diameter value, and as the coil is wound and unwound, the coil diameter value changes to adjust the proportion value P of the PID adjustment sub-module, so that the coil tension can be dynamically controlled more accurately. Specifically, at a constant linear speed, constant P (proportion) is taken, and at different diameters, different P (proportion) values are taken when the diameters of the rolls are large, medium and small; in acceleration and deceleration, different P (proportion) values are taken when the diameters are different and the diameters are corresponding to the large, medium and small coil diameters.

In another embodiment of the present invention, a second web tension control system is provided for controlling tension of a web during retraction, the system comprising a main controller and the following modules:

unlike the output line speed deviation DeltaV of the tension compensation adjustment module in the previous embodiment, as shown in FIG. 5, the tension compensation adjustment module in this embodiment outputs the rotation speed deviation DeltaN according to the following specific method:

and performing operation processing on the DIV operation result and the PID correction result to obtain a rotation speed deviation value delta N.

Similarly, performing DIV operation on a preset linear speed reference value and the roll diameter ratio data to obtain a rotating speed reference value;

then, the rotation speed deviation delta N, the rotation speed reference value and the rotation speed compensation value are added to obtain a rotation speed calibration target value; and controlling the output rotating speed of the driving mechanism for winding and unwinding the coiled material according to the rotating speed calibration target value.

The speed reference value is not limited to be output from the speed compensation adjustment module, for example, it may be output from an additional independent module (not shown), that is, a DIV operation is performed on the preset linear speed reference value and the winding diameter ratio data, a DIV operation is performed on the speed compensation result and the winding diameter ratio data output from the speed compensation adjustment module, and an operation process is performed on the DIV operation result and the PID correction result, so that a rotational speed deviation value Δn is three independent operation processes.

For another example, the speed reference value is output from the speed compensation adjustment module (as shown in fig. 1), and then the speed compensation result output by the speed compensation adjustment module and the roll diameter ratio data are subjected to DIV operation, and a preset linear speed reference value and the roll diameter ratio data are subjected to DIV operation to form an integral operation process, which comprises: performing operation processing on a preset linear velocity reference value and the velocity compensation result to obtain a compensated linear velocity target value; and performing DIV operation on the compensated linear velocity target value and the roll diameter ratio data, and performing addition processing operation on an operation result and a rotating speed deviation value delta N to obtain the rotating speed calibration target value.

For example, if the speed reference value is input to the tension compensation adjustment module and output from the tension compensation adjustment module (not shown), the real-time linear speed information and the winding diameter ratio data are subjected to DIV operation, and a preset linear speed reference value and the winding diameter ratio data are subjected to DIV operation, and the speed compensation result output by the speed compensation adjustment module and the winding diameter ratio data are subjected to DIV operation to obtain a rotation speed compensation value, and the integral operation process includes: performing operation processing on a preset linear velocity reference value and the real-time linear velocity information to obtain a corrected deviation linear velocity target value; and performing DIV operation on the linear velocity target value after the correction deviation and the roll diameter ratio data. And the operation result and the rotation speed compensation value are processed and operated to obtain the rotation speed calibration target value.

In one embodiment of the present invention, there is provided a web tension control method including the steps of:

The web tension control method provided in this embodiment belongs to the same inventive concept as the first web tension control system provided in the above-described embodiment, and the description of the first web tension control system is incorporated herein by reference in this embodiment of the control method.

In one embodiment of the present invention, a second web tension control method is provided, comprising the steps of:

The web tension control method provided in this embodiment belongs to the same inventive concept as the second web tension control system provided in the above-described embodiment, and the description of the second web tension control system is incorporated herein by reference in this embodiment of the control method.

It is noted that relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one … …" does not exclude the presence of other like elements in a process, method, article, or apparatus that comprises the element.

The foregoing is merely exemplary of the application and it should be noted that modifications and adaptations to those skilled in the art may be made without departing from the principles of the application and are intended to be comprehended within the scope of the application.

Claims

1. A coiled material tension control system for controlling tension of coiled material in a coiling and uncoiling process, which is characterized by comprising a main controller and the following modules:

the master controller of the web tension control system is configured to:

2. A coiled material tension control system for controlling tension of coiled material in a coiling and uncoiling process, which is characterized by comprising a main controller and the following modules:

the master controller of the web tension control system is configured to:

3. The web tension control system according to claim 2, wherein the speed compensation result outputted from the speed compensation adjustment module and the reel ratio data are subjected to DIV operation, and the preset linear speed reference value and the reel ratio data are subjected to DIV operation as two independent operation processes;

4. The web tension control system according to claim 2, wherein performing a DIV operation on the real-time linear velocity information and the reel ratio data, and performing a DIV operation on a preset linear velocity reference value and the reel ratio data are two independent operation processes;

5. The web tension control system of any one of claims 1-4, wherein the tension compensation adjustment module is further configured with an inertia adjustment sub-module that predicts an inertia compensation degree of the web based on a physical parameter of the web and adjusts the proportional value P of the PID adjustment sub-module based on the inertia of the web.

6. The web tension control system of any one of claims 1-4, wherein the system pre-constructs a mapping relationship between web roll diameter values and scaling factors, the roll diameter ratio calculation submodule further configured to calculate web roll diameter values from real-time linear and angular velocity information;

7. The web tension control system of any one of claims 1-4, wherein the tension compensation adjustment module is further configured to output the real-time linear velocity; the system calculates the acceleration value of the coiled material according to the real-time linear velocity;

8. The web tension control system of any one of claims 1-4, further comprising a linear velocity sensor configured to detect real-time linear velocity and an angular velocity sensor configured to detect real-time angular velocity.

9. A web tension control method comprising the steps of:

10. A web tension control method comprising the steps of:

11. The web tension control method according to claim 10, wherein the real-time linear velocity information and the reel ratio data are subjected to DIV operation, the velocity compensation value and the reel ratio data are subjected to DIV operation, and a preset linear velocity reference value and the reel ratio data are subjected to DIV operation as independent operation processes;